Hybrid pigmented hot stitched color liner system

ABSTRACT

A method of making a liner for an appliance is provided. The method includes mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer. The method also includes extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature. The method further includes laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/017,456, filed on Jun. 25, 2018, entitled HYBRID PIGMENTED HOTSTITCHED COLOR LINER SYSTEM, the disclosure of which is herebyincorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to liners for appliances. Morespecifically, the present disclosure generally relates to pigmentedliners for appliances.

BACKGROUND

This application relates to liners having particular colors, hues,tints, and the like which are desired for many appliance-relatedapplications, such as refrigeration appliances. As appliance designershave recently placed more emphasis on interior design and lighting(e.g., given the lower energy usage of light-emitting diode (LED)sources), the importance of interior aesthetics has increased for manyconsumers. Similarly, appliance manufacturers often emphasizeaesthetics, including interior design approaches, in attempting toobtain brand differentiation from their competitors.

Liners employed in appliances, including refrigeration appliances, areoften produced with extrusion processes. As these liners often arefabricated from two or more layers, conventional approaches to addingcolor to these liners often involve adding pigments to each extruderemployed in making a layer employed in the liner. As pigments are addedto multiple extruders, the complexity, repeatability, and manufacturingcost of matching colors increases significantly for a liner thatcomprises two or more layers having pigments. Further, as significantloadings of pigments in these multi-layer liners are often employed,down-stream processes such as thermal forming used to incorporate theliners into an end product can lead to local discoloration and yieldlosses. Further, multiple and cost-intensive extrusion runs are oftenrequired to fabricate a liner having multiple, extruded layers withpigments that match a particular color, tint, or hue. Still further,these approaches for making a liner having multiple, extruded pigmentedlayers require one or more adhesives to bond the layers, which increasesthe cost and can decrease manufacturing yield.

Colored liners currently being utilized in appliances frequently presentproblems during manufacturing since these liners readily show scratchesor defects in the liner surface where the pigment is incorporated. Suchscratches imparted on the liner during either the manufacturing processor use by consumers can lead to premature wearing where the insidesurface of the refrigeration appliance can look excessively worn ordamaged. The flexibility and ability to produce liners where scratchesare not readily shown would be beneficial to both manufactures and usersfor both the production process and downstream aesthetic appearances.

Accordingly, there is a need for methods of making liners, particularlypigmented liners for refrigeration appliances, which are repeatable,with high manufacturing flexibility, and low in cost. There is also aneed for pigmented liners that do not readily show scratches or otherwear marks that may be transferred to the liner surface duringfabrication or consumer use.

SUMMARY OF THE DISCLOSURE

In at least one aspect of the present disclosure, a method of making aliner for an appliance is provided. The method includes mixing apolymeric capping layer precursor and a pigment additive to form a colorcapping layer such that a pigment concentration in the color cappinglayer is at least about 10% by weight, wherein a thickness of the colorcapping layer is in the range of about 0.60 mm to about 0.80 mm;extruding a polymeric base resin to form a polymeric base layer at abase layer formation temperature; and laminating the polymeric baselayer and the color capping layer to form the liner at about the baselayer formation temperature.

According to another aspect of the present disclosure, a method ofmaking a liner for an appliance is provided. The method includes mixinga polymeric capping layer precursor and a pigment additive to form acolor capping layer such that a pigment concentration in the colorcapping layer is at least about 10% by weight, wherein a thickness ofthe color capping layer is in the range of about 0.60 mm to about 0.80mm; extruding a polymeric base resin to form a polymeric base layer at abase layer formation temperature; and laminating the polymeric baselayer and the color capping layer to form the liner at about the baselayer formation temperature, wherein the lamination is performed in theabsence of an adhesive.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe device, will be better understood when read in conjunction with theappended drawings. For the purpose of illustrating the device, there areshown in the drawings, certain embodiment(s) that are presentlypreferred. It should be understood, however, that the device is notlimited to the precise arrangements and instrumentalities shown.Drawings are not necessary to scale. Certain features of the device maybe exaggerated in scale or shown in schematic form in the interest ofclarity and conciseness.

In the drawings:

FIG. 1 is a schematic of a refrigeration appliance including a lineraccording to aspects of the present disclosure;

FIG. 2A is a schematic of an enlarged cross-section of the liner atregion II marked in FIG. 1 comprising a color capping layer, a barrierlayer, and a polymeric base layer, according to some aspects of thepresent disclosure;

FIG. 2B is a schematic of an enlarged cross-section of the liner atregion II marked in FIG. 1 comprising a color capping layer and apolymeric base layer according to some aspects of the presentdisclosure;

FIG. 2C is a schematic view on an enlarged cross-section of the liner atregion II marked in FIG. 1 comprising a color capping layer and apigmented polymeric base layer according to some aspects of the presentdisclosure;

FIG. 3A is a flow-chart schematic of a method for making a liner for anappliance according to some aspects of the present disclosure;

FIG. 3B is an illustrated schematic of the method for making a liner foran appliance according to some aspects of the present disclosure;

FIG. 4A is a schematic of a hot lamination process according to someaspects of the present disclosure;

FIG. 4B is a schematic of a hot lamination process according to otheraspects of the present disclosure; and

FIG. 5 is a schematic for shaping the liner into a final liner to beinstalled in a refrigeration appliance according to some aspects of thepresent disclosure.

DETAILED DESCRIPTION

Before the subject device is described further, it is to be understoodthat the device is not limited to the particular embodiments of thedevice described below, as variations of the particular embodiments maybe made and still fall within the scope of the appended claims. It isalso to be understood that the terminology employed is for the purposeof describing particular embodiments or aspects of embodiments, and isnot intended to be limiting. Instead, the scope of the present devicewill be established by the appended claims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range, and any other stated or intervening value in thatstated range, is encompassed within the device. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges, and are also encompassed within the device, subject toany specifically excluded limit in the stated range. Where the statedrange includes one or both of the limits, ranges excluding either orboth of those included limits are also included in the device.

In this specification and the appended claims, the singular forms “a,”“an” and “the” include plural reference unless the context clearlydictates otherwise.

Referring to FIGS. 1-5, a method 100 of making a liner 10 for anappliance 14 is provided. The method 100 includes mixing a polymericcapping layer precursor 15 and a pigment additive 16 to form a colorcapping layer 18 (step 104). The method 100 further includes extruding apolymeric base resin 20 to form a polymeric base layer 22 at a baselayer formation temperature (step 108). The method 100 may furtherinclude laminating a barrier layer 26 between the polymeric base layer22 and the color capping layer 18 to form the liner 10 at about the baselayer formation temperature (step 112). The method may additionallyinclude forming a textured pattern 24 on an outer surface 28 of thecolor capping layer 18 (step 116). The formed liner 10 includes acapping region 30, an optional barrier region 34, and a base region 38where the capping region 30 includes the pigment additive 16. The method100 additionally may include shaping the liner 10 into a final liner 74at a shaping temperature where the final liner 74 is configured and/oris suitable for assembly into a refrigeration appliance (step 120).

Referring now to FIG. 1, the refrigeration appliance 14 is provided inan exemplary form that includes the liner 10 according to some aspects.As shown, the liner 10 is mounted to a cabinet 42 of the refrigerationappliance 14. In some configurations, the liner 10 is mounted to a foamlayer 46 (see FIG. 2) installed on an interior surface of the cabinet42. In other configurations, the liner 10 may be mounted directly to thecabinet 42. Typically, the liner 10 is attached, coupled, joined, orotherwise fastened to the cabinet 42 through the insulating foam 46,adhesive, bonding agent, mechanical fastener (e.g., rivets, screws,etc.) or another comparable approach. However, the liner 10 itself doesnot include any internal adhesives and, according to some aspects,includes one or more pigment additives 16 in the color capping layer 18only (see FIGS. 2A-2B).

Referring now to FIG. 2A, the liner 10 (e.g., as incorporated into theappliance 14 depicted in FIG. 1) includes the color capping layer 18 andcorresponding capping region 30, the polymeric base layer 22 andcorresponding base region 38, and the barrier layer 26 and correspondingbarrier region 34. The liner 10 and its combination of the barrier layer26 sandwiched between the color capping layer 18 and polymeric baselayer 22 may be positioned directly onto the foam layer 46. In someaspects, the foam layer 46 may include closed-cell and/or open-cellvoids, air bubbles, and/or pores 50 distributed evenly throughout thefoam layer 46. In some aspects, the foam layer 46 imparts an insulationlayer between the liner 10 and the wrapper and/or cabinet 42 of theappliance 14.

The polymeric capping layer precursor used to form the color cappinglayer 18 may include a high-impact polystyrene (HIPS),polymethylmethacrylate (PMMS), polystyrene (PS), acrylonitrile butadienestyrene (ABS), polyurethane (PU), polypropylene (PP), polyethylene (PE),or combinations thereof. In some aspects, the polymeric capping layerprecursor selected for use in the color capping layer 18 may be anyknown thermoplastic known in the art suitable for use in an extrusionprocess. In other aspects, the polymeric capping layer precursor used toform the color capping layer 18 may include a high-impact polystyrene(1115 HIPS) precursor material. As also depicted in FIG. 2A, the colorcapping layer 18 can be configured to have a thickness 54 (e.g., throughextrusion, rolling, etc.) of about 0.10 mm to about 1.5 mm. In someaspects, the thickness 54 of the color capping layer 18 may range fromabout 0.25 mm to about 0.75 mm. Note that the thickness 54 of the colorcapping layer 18 is given in approximate dimensions, as would betypically associated with the color capping layer 18 being in a sheet orlayer form before incorporation into the liner 10. The pigment additive16 may be incorporated and/or disbursed within the color capping layer18 at a level sufficient to impart a desired color, hue, tinting, or thelike in the liner 10.

Still referring to FIG. 2A, the textured pattern 24 may be positioned onthe outer surface 28 of the color capping layer 18 of the liner 10. Thetextured or granular pattern 24 is beneficial for the color andaesthetic preservation of the liner 10 over time since the texturedpattern 24 can help protect the color capping layer 18 from visiblyshowing scratches, rub marks, gouges, and/or scrapes. The texturedpattern 24 may include a variety of different surface patterns formed onthe colored capping layer 18, for example, pyramidal, diamond, circular,trapezoidal, square, tetragonal, hexagonal, polygonal, or a combinationof shapes thereof. In some aspects, the textured pattern 24 may includea 2D surface pattern, a 3D surface pattern, or a combination thereof.The textured or granular pattern 24 helps prevent visible markings orwear of the outer surface 28 of the liner 10 by offering an alternativeto a glossy or smooth finished surface that can readily show marks orwear from the manufacturing process or normal wear. In some aspects, thetextured or granular pattern 24 can absorb a scratch, scuff, and/orgouge while the textured pattern 24 can blend in or camouflage therespective mark. In some examples, the textured pattern 24 may beomitted such that the outer surface 28 is provided with a smoothappearance.

Still referring to FIG. 2A, the color capping layer 18 of the liner 10may include one or more pigment additives 16, configured to impartcolor, tinting, or the like into the liner 10. As understood by thosewith ordinary skill in the field of the disclosure, various metallic,ceramic, polymeric pigments, and colorants can be added at variousconcentrations within the polymeric capping layer precursor employed inthe color capping layer 18 of the liner 10. In some aspects, the pigmentadditive 16 is a granulated pigment. For example, titanium oxide can beincluded as the pigment additive 16 to achieve a white color. In otheraspects, the liner 10 having a charcoal-sparkle appearance can becreated by employing carbon black in one or more of quartz, mica, andstainless steel as the pigment additive 16. In some aspects of thedisclosure, the pigment additives 16 are incorporated into the cappingregion 30 of the color capping layer 18 at a concentration level anddisbursed to ensure that the liner 10 exhibits a particular color, hue,or the like, as desired by the user of the appliance 14. In someaspects, no additional pigment additives 16 are used, directly orindirectly transferred, and/or incorporated in the base region 38 of thepolymeric base layer 22 to obtain the desired color, hue, or tinting forthe liner 10. According to other aspects, the pigment additives 16 maybe incorporated into the capping region 30 and the base region 38 atconcentrations sufficient for the liner 10 to obtain the desired color,hue, or tinting. In some aspects, the mixing step 104 includes mixingthe polymeric capping layer precursor with about 5% to about 30% pigmentadditive 16 by weight of the color capping layer 18. According to someaspects, the pigment additives 16 are incorporated into the cappingregion 30 of the color capping layer 18 at a concentration from about10% to about 25% (by weight of the capping layer 18). Optionally, thepigment additives 16 may be incorporated into the capping region 30 at aconcentration from about 1% to about 10% (by weight of the capping layer18). In still other aspects, the concentration of the pigment additive16 in the capping region 30 of the color capping layer 18 is loadedbetween about 15% to about 25% (by weight of the capping layer 18) andin the base region 38 of the polymeric base layer 22, if present, fromabout 3% to about 5% (by weight of the base layer 22). In some aspects,the color capping layer comprises from about 70% to about 95% by weightpolymeric capping layer precursor and from about 5% to about 30% pigmentadditive by weight.

Still referring to FIG. 2A, the barrier layer 26 and correspondingbarrier region 34 may help protect the liner 10 from wrinkling,deformations, and/or delamination effects caused during manufacturing orend use. In some aspects, the barrier layer 26 may prevent the diffusionof volatiles and other potential contaminants associated with injectingthe foam 46 positioned between the liner 10 and the cabinet 42. In someaspects, the contaminants associated with the foam 46 that coulddiscolor or lead to other deteriorating defects in the liner 10 have nonegative effects on the color capping layer 18 disclosed herein. Thebarrier layer 26 may be sandwiched directly between the color cappinglayer 18 and polymeric base layer 22 to form the liner 10 with noadditional adhesives and/or bonding agents used between the respectivelayers 18, 22, 26. In some aspects, the barrier region 34 includes apolyethylene material used in combination with a material employed inthe base region 38, typically a material comparable to that employed inthe capping layer 18 or capping region 30, e.g., a high-impactpolystyrene (HIPS). In some aspects, the barrier layer 26 may be formedusing a low density polyethylene, a high density polyethylene, apolypropylene, a polycarbonate, a polyester, a polyamide, a polystyrene,a high-impact polystyrene (HIPS), or a combination thereof. According tosome aspects, additional compatibilizers, as understood by those withordinary skill in the art, are added to the barrier region 34 to ensurethat the polyethylene layers and HIPS material within the barrier region34 are combined without the formation of voids, bubbles, delaminationdefects, etc. In some aspects, the barrier region 34 may include one ormore barrier layers 26 comprising a polyethylene material, layered onthe respective material of the base layer 22. As also depicted in FIG.2, the barrier region 34 of the barrier layer 26 can be configured witha thickness 58 (e.g., through extrusion, rolling, etc.) of about 0.10 mmto about 1.5 mm. In some aspects, the barrier layer 26 has a thickness58 of about 0.25 mm to about 0.75 mm. Note that the thickness 58 of thebarrier layer 26 is given in approximate dimensions, as would betypically associated with the barrier layer 26 being in a sheet or layerform before incorporation into the liner 10.

Referring to FIG. 2A, the polymeric base layer 22 may provide structuralsupport to the liner 10 in addition to spacing the pigment additives 16of the color capping layer 18 away from the surface of the liner 10. Byputting distance or space between the outer surface of the liner 10 andthe color capping layer 18, no contact may be made between the moredelicate colored capping layer 18 and the user and/or potential foodproducts stored in the appliance 14. The polymeric base resin 20 used toform the base region 38 of the polymeric base layer 22 may include ahigh-impact polystyrene (HIPS), polymethylmethacrylate (PMMS),polystyrene (PS), acrylonitrile butadiene styrene (ABS), polyurethane(PU), polypropylene (PP), polyethylene (PE), or combinations thereof. Insome aspects, the polymeric base resin 20 selected for use in the baselayer 22 are thermoplastics, suitable for use in an extrusion process.In other aspects, the polymeric base resin 20 (see FIGS. 4A and 4B) usedto form the polymeric base layer 22 may include a high-impactpolystyrene (1170 HIPS) precursor material. As also depicted in FIG. 2A,the base region 38 of the polymeric base layer 22 can be configured witha thickness 62 (e.g., through extrusion, rolling, etc.) of about 0.10 mmto about 1.5 mm. In some aspects, the polymeric base layer 22 hasthickness 62 of about 0.25 mm to about 0.75 mm. Note that the thickness62 of the base layer 22 is given in approximate dimensions, as would betypically associated with the polymeric base layer 22 being in a sheetor layer form before incorporation into the liner 10.

Still referring to FIG. 2A, the liner 10 is configured such that thecapping region 30, the barrier region 34, and the base region 38 (i.e.,for liner 10) are joined with substantially no interfaces between them.The term “interface”, as defined herein, is meant to include boundariesmarked by structural defects such as cracks, folds, or bubbles where twolayers (e.g. 18, 22, and 26) meet and interact. When layers made fromdifferent polymeric materials (e.g. 18, 22, and/or 26) are laminatedtogether, the blending of the respective polymeric materials at thejunction between the layers is not considered an “interface” because theboundary is not marked by one or more defects that may lead to adecrease in structural integrity. In some aspects, the liner 10,including the capping region 30, the barrier region 34, and/or the baseregion 38 are joined with substantially no interfaces between therespective layers forming a uniform bilayer or trilayer with theappearance of a monolayer. That is, a cross-section of the liner 10 whenviewed under low magnification will not reveal any indications of aninterface or interfaces between the capping region 30, the barrierregion 34, and/or the base region 38. Advantageously, the lack of anyappreciable interfaces between these two or three regions significantlyreduces the likelihood that these regions will delaminate duringsubsequent processing (e.g., thermal-forming of the liner 10 into arefrigeration appliance 14, such as depicted in FIG. 1) and otherdemands of the application environment of the liner 10. Anotheradvantage of these liners 10 is that the base region 38, the barrierregion 34, and/or the capping region 30 for the liner 10 are configuredwith substantially no interfaces between them, thus eliminating thenecessity of employing adhesives or other bonding agents to join them.As these implementations of the liner 10 do not require adhesives, theycan be fabricated, e.g. through lamination processes, at a lower costand using faster fabrication processes. Further, the lack of adhesivesemployed between these regions tends to result in improved coloruniformity for these liners 10 in comparison to conventional, pigmentedmulti-layer liners with layers joined with internal adhesives. In someaspects, the interfaces between the barrier layer 26 and the base layer22, the barrier layer 26 and the capping layer 18, and/or between thebase layer 22 and the capping layer 18 include a polymer blend where therespective polymeric resins used in the respective layers flow and mixto form the corresponding polymer blends at the interface.

Referring now to FIGS. 2B and 2C, in some aspects, the liner 10 may notinclude the barrier layer 26 and corresponding barrier region 34. Theliner 10 without the barrier layer 26 includes the color capping layer18 having pigment additives 16 evenly dispersed throughout. The colorcapping layer 18 additionally includes the outer surface 28 having thetextured pattern 24 and an inner surface directly coupled or layeredonto the polymeric base layer 22. The polymeric base layer 22 may bepositioned directly onto the foam layer 46 having one or more voids 50where the foam layer 46 is sandwiched directly between the polymericbase layer 22 and the wrapper and/or cabinet 42. In some examples, thebase layer 22 may include the pigment additives 16 dispersed throughout.For example, the base layer 22 may be provided with a lowerconcentration of the pigment additive 16 than the concentration that isprovided in the color capping layer 18. In one specific example, thecolor capping layer 18 may be provided with a composition of 70% HIPSand 30% pigment additive 16 while the base layer 22 is provided with acomposition of 70% HIPS and 30% PE mixture, where the PE mixture has acomposition of 96% PE and 4% pigment additive 16. However, the presentdisclosure is not so limited. For example, the PE mixture may beprovided with a composition that utilizes the pigment additive 16 at aconcentration of at least about 1%, at least about 5%, at least about10%, at least about 15%, at least about 20%, at least about 25%, atleast about 30%, and/or combinations or ranges thereof, with a balancingconcentration of polyethylene (PE). It may be beneficial to provide thepigment additive 16 in the base layer 22 at a concentration that isequal to, or generally corresponds with (e.g., within about 10%), theconcentration of the pigment additive 16 in the color capping layer 18.The capping layer thickness 54 and base layer thickness 62 may includethe same thickness values described herein. Advantages of not using thebarrier layer 26 in the liner 10 can include a reduction in weight, areduction in liner 10 thickness, and/or a simpler and more efficientmanufacturing process.

Referring now to FIGS. 3A and 3B, the method 100 of making the liner 10for the refrigeration appliance 14 is depicted in schematic form. Themethod 100 includes the mixing step 104 for mixing the polymeric cappinglayer precursor and the pigment additive 16 to form the color cappinglayer 18. In some aspects, the mixing step 104 includes mixing thepolymeric capping layer precursor with about 5% to about 30% pigmentadditive 16 by weight or from about 15% to about 25% pigment additive 16by weight of the capping layer 18. The mixing step 104, for example, canbe conducted within an extruder or in a separate vessel or container.According to some aspects, the mixing step 104 is conducted such thatthe polymeric capping layer precursor and the pigment additive 16 aremixed in particulate form. In some aspects, the mixing step 104 isconducted such that the color capping layer 18 exhibits a predeterminedcolor. In some aspects, the color capping layer 18 includes thepolymeric capping layer precursor from about 50% to about 98% by weight,from about 60% to about 95% by weight, from about 70% to about 95% byweight, or from about 75% to about 95% by weight of the color cappinglayer 18.

Referring again to FIGS. 3A and 3B, the method 100 of making the liner10 for the appliance 14 further includes the extruding step 108 forforming the polymeric base layer 22. In some aspects, the extruding step108 is conducted in an extruder suitable for extrusion of thermoplasticmaterials into polymeric layers. According to some aspects, the baselayer formation temperature is set between about 120° F. to about 425°F., about 120° F. to about 160° F., from about 275° F. to about 400° F.,or from about 290° F. to about 370° F. In other aspects, the extrudingstep 108 is conducted with other apparatuses to accomplish the same orsimilar function as would be understood by those with ordinary skill inthe art, e.g., hot-pressing apparatus, injection molding apparatus, etc.

Still referring to FIGS. 3A and 3B, the method 100 of making the liner10 of the appliance 14 further includes the laminating step 112 forlaminating the barrier layer 26 between the color capping layer 18 andthe polymeric base layer 22 to form the liner 10 at about the base layerformation temperature. According to some aspects of the disclosure, thelaminating step 112 of the method 100 is conducted by using rollers,e.g. one or more calendaring rollers 70 (see FIGS. 4A and 4B).Accordingly, the laminating step 112 using rollers can involve rollingthe polymeric base layer 22, the color capping layer 18, and the barrierlayer 26 together, at about the base layer formation temperature to formthe liner 10. By rolling these layers together at about the sametemperature in which they were extruded or otherwise processed inearlier steps, the laminating step 112 ensures that these layers arejoined together with substantially no interfaces between them. In someaspects, the liner 10 can be characterized as a bilayer or trilayerappearing as a monolayer having substantially no interfaces between thetwo or three respective regions 30, 34, and/or 38. In some aspects, thelamination step 112 is conducted to form the liner 10 havingsubstantially no interfaces between the capping region 30, the barrierregion 34, and the base region 38. In some aspects, the laminating stepis conducted such that the color capping layer 18 exhibits apredetermined color.

In some aspects, the lamination step 112 can be heated to about the baselayer formation temperature, e.g., about 275° F. to about 400° F. Thatis, a temperature that is about the base layer formation temperatureallows for efficient laminating of the respective layers 18, 22, and 26.In some aspects, temperatures considered “about the base layer formationtemperature” include temperatures less than or equal to 3° F., less thanor equal to 5° F., less than or equal to 10° F., or less than or equalto 15° F. of the melting temperature of the polymeric base resin 20 orblend used. The pressure applied by the rollers in the lamination step112, and the fact that the rollers are set to approximately the baselayer formation temperature, ensures that the capping layer 18, baselayer 22 and barrier layer 26 are merged together during the laminationstep 112 to form the uniform liner 10.

Referring again to FIGS. 3A and 3B, the method 100 of making the liner10 can be conducted with an additional shaping step (step 120) afterformation of the liner in steps 104, 108, 112, and 116. Step 116 mayinclude sub-steps 116 a and 116 b, as depicted in FIG. 5 according tosome aspects of the present disclosure. Referring now to FIG. 5, thestep 120 of method 100 can be conducted by shaping the liner 10 into afinal liner 74 using a shaping temperature suitable for subsequentassembly into the refrigeration appliance. To impart a desired shape tothe liner 10, the liner 10 may be heat pressed or compression moldedbetween a heated top mold 72 a and a heated bottom mold 72 b (step 120a). The final liner 74 is formed to a desired shape/design and isconfigured for assembly into the appliance 14 (e.g., the refrigerationappliance 14 as shown in FIG. 1). In some aspects, the shaping step 120is conducted according to a thermal-forming process, typically at atemperature that approaches, but does not exceed, the base layerformation temperature, employed in earlier steps of the method 100. Insome aspects, the shaping temperature of the shaping step may rangebetween temperatures from about 200° F. to about 350° F.

Referring now to FIGS. 4A and 4B, in some aspects, the method 100 ofmaking the liner 10 of the appliance 14 may reduce energy usage andtiming needs by directly extruding the polymeric base resin 20 andcorresponding polymeric base layer 22 into a laminating assembly 64. Inthese aspects, as the polymeric base layer 22 is freshly formed using anextruder 66 where the polymeric base layer 22 is still hot from theextrusion and forming processes, the polymeric base layer 22 is directlypositioned into the laminating assembly 64 contemporaneously with thecolor capping layer 18 and barrier layer 26 loaded from a pulley roller68 to be laminated into the liner 10 using one or more rollers 70. Atleast one of the advantages of laminating the freshly formed and stillhot polymeric base layer 22 with the color capping layer 18 and barrierlayer 26 is the ability to save energy from not having to heat each ofthe respective layers 18, 22, 26 to about the base layer formationtemperature. Since the temperature of the polymeric base layer 22 isabout the base layer formation temperature upon being formed, thepolymeric base layer 22 may be readily laminated to the barrier layer 26and color capping layer 18 to form the liner 10 with substantially nointerfaces between the respective layers (see FIG. 2A). In some aspects,no barrier layer 26 may be incorporated and the polymeric base layer 22may be readily and directly laminated to the color capping layer 18 toform the liner 10 with substantially no interfaces between therespective layers (see FIG. 2B). In some aspects, the base layerformation temperature may be from about 120° F. to about 160° F., fromabout 125° F. to about 350° F., from about 175° F. to about 325° F., orfrom about 200° F. to about 275° F. In some aspects, the base layerformation temperature is above their glass transition temperature foramorphous polymers or when the amorphous polymer begins to flow and/orabove their melting point for crystalline polymers or when thecrystalline polymer begins to flow.

Still referring to FIGS. 4A and 4B, the method 100 of making the liner10 includes forming the textured pattern 24 on the outer surface 28 onthe color capping layer 18 (step 116). In some aspects, the texturedpattern 24 may be formed into the outer surface 28 on the color cappinglayer 18 using a granular pattern mold roller 70 a. Depending on thedesired aesthetic and color appearance desired for the liner 10, thegranular pattern mold roller 70 a can be configured to impart or mold,for example, pyramidal, diamond, circular, trapezoidal, square,tetragonal, hexagonal, polygonal, or a combination of shapes thereofinto the outer surface 28 of the color capping layer 18. In someaspects, the textured pattern 24 may include a 2D surface pattern, a 3Dsurface pattern, or a combination thereof. The added textured orgranular pattern 24 helps maintain color, prevent visible markings,and/or prevent visible wear of the outer surface 28 of the liner 10 byoffering an alternative to a glossy or smooth finished surface thatreadily can show marks or wear from the manufacturing process or normalwear.

Referring further to FIGS. 4A and 4B, in some aspects of the presentdisclosure, the liner 10 is provided with the color capping layer 18 andthe base layer 22 while the barrier layer 26 is excluded. The polymericbase resin 20 used to form the polymeric base layer 22 may include ahigh-impact polystyrene (HIPS) precursor material, such as 1170 HIPS, aswell as polyethylene (PE). For example, the base layer 22 may include amixture of 70% high-impact polystyrene (HIPS) and a polyethylene (PE)mixture. The polyethylene (PE) mixture may include a loadingconcentration of high-impact polystyrene (HIPS). For example, thepolyethylene (PE) mixture may include a loading concentration ofhigh-impact polystyrene (HIPS) of at least about 2% HIPS, at least about4% HIPS at least about 6% HIPS, at least about 8% HIPS, at least about10% HIPS, at least about 12% HIPS, at least about 14% HIPS, at leastabout 16% HIPS, at least about 18% HIPS, at least about 20% HIPS, and/orcombinations or ranges thereof. Accordingly, one specific example of thecomposition of the base layer 22 may be 70% HIPS and 30% PE mixture,where the PE mixture has a composition of 90% PE and 10% HIPS by weight.The color capping layer 18 may have a composition similar to thosedescribed herein, such as high-impact polystyrene (HIPS) with a loadingconcentration of the pigment additive 16 (see FIG. 2B). For example, thecolor capping layer 18 may be made with a composition that includeshigh-impact polystyrene (HIPS) at a concentration in the range of atleast about 70% to less than about 99% and a loading of the pigmentadditive 16 of at least about 1% to less than about 30%.

Referring still further to FIGS. 4A and 4B, in some aspects of thepresent disclosure, the color capping layer 18 and the base layer 22 mayeach be provided with the pigment additive 16 (see FIG. 2C). In such anexample, the base layer 22 may be provided with a lower concentration ofthe pigment additive 16 than the concentration that is provided in thecolor capping layer 18. In one specific example, the color capping layer18 may be provided with a composition of 70% HIPS and 30% pigmentadditive 16 while the base layer 22 is provided with a composition of70% HIPS and 30% PE mixture, where the PE mixture has a composition of96% PE and 4% pigment additive 16. However, the present disclosure isnot so limited. For example, the PE mixture may be provided with acomposition that utilizes the pigment additive 16 at a concentration ofat least about 1%, at least about 5%, at least about 10%, at least about15%, at least about 20%, at least about 25%, at least about 30%, and/orcombinations or ranges thereof, with a balancing concentration ofpolyethylene (PE). It may be beneficial to provide the pigment additive16 in the base layer 22 at a concentration that is equal to, orgenerally corresponds with (e.g., within about 10%), the concentrationof the pigment additive 16 in the color capping layer 18. The colorcapping layer 18 may be provided with any of the compositions disclosedherein, including combinations thereof without departing from theconcepts disclosed herein. Additionally, the base layer 22 may beprovided with any one of the compositions disclosed herein orcombinations thereof. Further, the base layer 22 may be provided with acomposition that is a hybrid of the compositions disclosed herein forthe color capping layer 18, the base layer 22, and/or the barrier layer26. By providing the base layer 22 with the pigment additive 16, in theevent of defects or deformations to the liner 10, the defects ordeformations may be at least partially blended with the surrounding areasuch that the defect or deformation remains hidden or barely perceptibleto the user.

One function of the barrier layer 26, is to protect the color cappinglayer 18 from defects and deformations that result from the foam layer46 attacking or degrading the base layer 22. The foam layer 46, in someinstances, can penetrate through the base layer 22 and interact directlywith the barrier layer 26. In the bilayer examples disclosed herein, thebarrier layer 26 is omitted. Accordingly, the foam layer 46 may pose agreater threat to the integrity of the color capping layer 18 if thefoam layer 46 is allowed to interact with the color capping layer 18.Therefore, the formulation of the base layer 22 in its various aspectsand examples has been designed as a hybrid composition that may beprovided with characteristics of both the base layer 22 and the barrierlayer 26 while remaining a uniform composition. By adjusting thecomposition of the base layer 22, the foam layer 46 is not permitted toreduce the thickness of the liner 10 prior to the progress of the foamlayer 46 being halted by the barrier layer 26. Instead, the base layer22 immediately resists the progress of the foam layer's 46 degradationof the liner 10. An additional advantage of the bilayer structure isthat the color capping layer 18 and the base layer 22 are more suitablefor regrinding of scrap material such that manufacturing costs arereduced. In addition to significant manufacturing cost savings byopening the possibility for regrinding of scrap material, the presentdisclosure significantly reduces the complexity of the productionprocess by laminating the liner 10 as a bilayer. By laminating twolayers together rather than three, fewer opportunities exist fordefects, deformations, and imperfections in the liner 10. For example,laminating a third layer onto a bilayer can result in deformations innot only the junction between the third layer and the bilayer, but alsocan result in a disruption in the junction between first and secondlayers that have already been laminated into the bilayer. The use of thebilayer and the hybrid composition for the base layer 22 are able todecrease cost and waste while maintaining or improving a lifecycle ofthe liner 10, which ultimately can decrease costs associated withrecalls and/or warranty repairs. The hybrid composition of the baselayer 22 prevents deformation, defects, and general depolymerization ordissolving of the base layer 22 that can result from insulating foamsthat are often utilized in the appliance 14. Accordingly, the hybridcomposition of the base layer 22 can reduce or eliminate the drawbacksof utilizing a separate barrier layer 26 while maintaining the benefitsprovided by the barrier layer 26.

Trilayer structures that employ the barrier layer 26 may be providedwith compositions that include a mixture of polyethylene (PE) andpolyethylene terephthalate (PET). For example, the barrier layer 26 maybe provided with a composition of 90% PE (e.g., 1170 HIPS) and 10% PET.While the incorporation of the barrier layer 26 helps to protect againstwrinkling and other deformations, the barrier layer 26 can introducedifficulties with manufacturing, costs, and performance of the liner 10.For example, the barrier layer 26 is often blended and produced as aseparate layer for the trilayer structures, which increases costs, andthe barrier layer 26 is often difficult or impossible to regrind whenissues arise. When polyethylene terephthalate (PET) is present in thebarrier layer 26, and the scrap barrier layer 26 is mixed with the colorcapping layer 18 and/or the base layer 22 for remanufacturing, thenserious issues arise with thermoforming and color matching of the liner10.

Referring to FIG. 5, the final liner 74 may be assembled with a wrapper78 (e.g. the cabinet 42 as shown in FIG. 1) and a trim breaker 82 toform an insulation structure (step 120 b). The insulation structure maythen be filled with the foam layer 46 or other insulative material knownin the art to form the fully insulated cabinet 42 structure.

The method 100 of making liners 10 and their corresponding bilayer ortrilayer structures result in liners 10 having better surface propertiesto prevent scratching or other visible aberrations of the color and/ortexture. For example, the barrier layer 26 in combination with thetextured pattern 24 positioned on the outer surface 28 of the liner 10hides visible scratches or markings on the color capping layer 18. Theability to position the pigment additive 16 and the color capping layer18 on one side of the liner 10 with the textured pattern 24 positionedon the outer surface 28 of the liner 10 allows the imparted color,tinting, hue or the like from visibly showing damage during themanufacturing or end use of the appliance 14.

It is understood that the descriptions outlining and teaching the methodof making the liner 10 previously discussed, which can be used in anycombination, apply equally well to the liner 10 for the appliance 14.Accordingly, the liner 10 includes a polymeric liner having the bilayeror trilayer structure where the bilayer or trilayer structure includes:the color capping layer 18 including a high-impact polystyrene materialand the pigment additive 16 wherein the outer surface 28 of the colorcapping layer 18 may include the textured pattern 24; the polymeric baselayer 22 including a high-impact polystyrene material and optionally thepigment additive 16; and, in some examples, the barrier layer 26including a polyethylene material wherein the barrier region 34 isdisposed between the color capping layer 18 and the polymeric base layer22. The color capping layer 18, barrier layer 26, and the polymeric baselayer 22 are directly coupled with substantially no interfaces betweenthem in the trilayer structure. The color capping layer 18 and thepolymeric base layer 22 are directly coupled with substantially nointerfaces between them in the bilayer structure.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above aremerely for illustrative purposes and not intended to limit the scope ofthe device, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method of making a liner for an appliance, themethod comprising: mixing a polymeric capping layer precursor and apigment additive to form a color capping layer such that a pigmentconcentration in the color capping layer is at least about 10% byweight, wherein a thickness of the color capping layer is in the rangeof about 0.60 mm to about 0.80 mm; extruding a polymeric base resin toform a polymeric base layer at a base layer formation temperature; andlaminating the polymeric base layer and the color capping layer to formthe liner at about the base layer formation temperature.
 2. The methodof claim 1, wherein the thickness of the color capping layer is in therange of about 0.70 mm to about 0.80 mm.
 3. The method of claim 2,wherein the thickness of the color capping layer is in the range ofabout 0.75 mm to about 0.80 mm.
 4. The method of claim 1, furthercomprising: mounting the liner to a foam layer of the appliance.
 5. Themethod of claim 1, further comprising: mounting the liner to a cabinetof the appliance.
 6. The method of claim 1, wherein the step oflaminating the polymeric base layer and the color capping layer to formthe liner at about the base layer formation temperature is performed inthe absence of an adhesive.
 7. The method of claim 1, wherein thepolymeric base layer comprises from about 1% to about 30% of the pigmentadditive by weight.
 8. The method of claim 1, wherein the base layerformation temperature is in the range of about 120° C. to about 160° C.9. The method of claim 1, wherein the mixing step is conducted with anextruder.
 10. The method of claim 1, wherein the laminating step isconducted with one or more calendaring rollers.
 11. The method of claim1, further comprising: forming a textured pattern on an outer surface ofthe color capping layer.
 12. The method of claim 1, further comprising:shaping the liner into a final liner at a shaping temperature.
 13. Themethod of claim 12, wherein the final liner is suitable for assemblyinto a refrigeration appliance.
 14. The method of claim 1, wherein thecolor capping layer and the polymeric base layer are each formed usingat least one component chosen from a high-impact polystyrene (HIPS), apolymethylmethacrylate (PMMS), a polystyrene (PS), an acrylonitrilebutadiene styrene (ABS), a polyurethane (PU), a polypropylene (PP), apolyethylene (PE), or a combination thereof.
 15. A method of making aliner for an appliance, the method comprising: mixing a polymericcapping layer precursor and a pigment additive to form a color cappinglayer such that a pigment concentration in the color capping layer is atleast about 10% by weight, wherein a thickness of the color cappinglayer is in the range of about 0.60 mm to about 0.80 mm; extruding apolymeric base resin to form a polymeric base layer at a base layerformation temperature; and laminating the polymeric base layer and thecolor capping layer to form the liner at about the base layer formationtemperature, wherein the lamination is performed in the absence of anadhesive.
 16. The method of claim 15, wherein the thickness of the colorcapping layer is in the range of about 0.70 mm to about 0.80 mm.
 17. Themethod of claim 16, wherein the thickness of the color capping layer isin the range of about 0.75 mm to about 0.80 mm.
 18. The method of claim15, further comprising: mounting the liner to a foam layer of theappliance.
 19. The method of claim 15, further comprising: mounting theliner to a cabinet of the appliance.
 20. The method of claim 15, whereinthe base layer formation temperature is in the range of about 120° C. toabout 160° C.